Hollow Handle Flatware and Method of Making a Hollow Handle Flatware

ABSTRACT

A hollow handle flatware includes a main body extending between a service end and a handle end. The main body includes a service portion at the service end and a handle portion at the handle end. The hollow handle flatware also includes a handle part, which is formed separately from the main body and permanently fixed to the handle portion of the main body to form a hollow handle. The handle part and the handle portion of the main body enclose a hollow chamber. Also disclosed is a method of making a hollow handle flatware by separately forming a main body and a handle part and joining the main body and the handle part as a unitary hollow handle flatware.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates generally to flatware and, in particular, to hollow handle metal flatware. Moreover, the invention relates to a method of making hollow handle metal flatware.

2. Description of the Related Art

Various flatwares have been formed with hollow handles, such as to provide an enlarged handle for an ergonomic grip by the user while reducing both the weight of the flatware and the material consumption for making the flatware. As is shown in FIGS. 1A and 1B, a conventional flatware 1 is typically formed with a service member 10 and a handle member 20 fixed to each other through a joint 30. The conventional flatware can be a fork or spoon; a fork being shown as an example in the figures. For the illustrated fork, the service member 10 will include fork tines 12. The service member 10 includes a connecting end 14 opposite from the fork tines 12 (FIG. 2A).

The handle member 20 of the flatware 1 is made of two handle sections 20 a, 20 b joined to each other in receiving arrangement with connecting end 14. The upper and lower handle sections 20 a, 20 b have respective connecting edges 22 a, 22 b joined to each other in the finished flatware 1. The respective outside surfaces 24 a, 24 b of the upper and lower handle sections 20 a, 20 b can be formed in various decorative shapes and/or with various decorative patterns. As FIGS. 3B and 3C show, the outside surfaces 24 a, 24 b of the handle sections 20 a, 20 b can each have a convex shape so as to form a bulged handle member 20 for an ergonomic grip of the flatware 1.

The various components of the flatware 1 can be formed by various ways. For example, the service member 10 can be formed by stamping a sheet material, resulting in a substantially flat shape as is shown in the side view of FIG. 2B.

The handle member 20 can be formed by joining the two handle sections 20 a, 20 b to each other. Each of the handle sections 20 a, 20 b have longitudinal shell shapes, as is illustrated by the arch shaped cross-section shown in FIG. 3C. The flatware is assembled by positioning the longitudinal joining edges 22 a, 22 b of each shell shaped handle section 20 a, 20 b such that they are opposite each other, receiving connecting end 14 therebetween such that the service member tines 12 extend from an end of the handle sections, and then securing the three pieces together. Welding is typically used for this purpose. FIG. 3D shows a joint 30, such as a welding line, connecting the two handle sections 20 a, 20 b and the service member. The handle member 20 has a connecting end 26 through which the connecting end 14 on the service member 10 extends, whereupon it is attached at that location.

In the conventional flatware 1, the joint 30 between the service member 10 and the handle member 20 often becomes weakened through use and by bending of the flatware. Additionally, manufacture of the conventional flatware 1 is cumbersome because it requires joining three components to each other, with two of the components, namely, the handle section, being aligned properly about the connecting end 14 before welding.

Accordingly, it is desirable to provide a flatware that can improve the strength at the joint between the handle sections and the service member and that can be easily manufactured.

SUMMARY OF THE INVENTION

A hollow handle flatware is described having a main body with a service portion and a handle portion which are integrally formed with each other. The main body has a length substantially defining a length of the hollow handle flatware, and the handle portion has an upper surface and a bottom surface. The bottom surface is configured for positioning on a table top. A handle part is formed separately from the main body and permanently fixed to the upper surface of the handle portion of the main body to form a hollow handle. The handle part and the handle portion of the main body enclose a hollow chamber therebetween.

In one embodiment main body includes a step formed on the upper surface of the main body between the service portion and the handle portion for receiving a front edge of the handle part.

In another embodiment the handle portion of the main body is configured as a substantially flat contact portion for contacting a tabletop surface when the hollow handle flatware is set on the tabletop surface. The contact portion on the handle portion of the main body extends across a width of the handle portion of the main body.

A method is also disclosed for making hollow handle flatware. The method includes the steps of providing a main body having a service portion and a handle portion which are integrally formed with each other. The main body has a length substantially defining a length of the hollow handle flatware, and the handle portion has an upper surface and a bottom surface, the bottom surface configured for positioning on a table top. The method includes providing a handle part separately from the main body, and permanently fixing the handle part to the upper surfaced of the handle portion of the main body. The handle part and the handle portion of the main body enclose a hollow chamber therebetween.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a plan view of a conventional flatware;

FIG. 1B is a partial side cross-sectional view of the conventional flatware in FIG. 1A;

FIG. 2A is a plan view of the service member of the flatware in FIG. 1A;

FIG. 2B is a side cross-sectional view of the service member shown in FIG. 2A;

FIG. 3A is a plan view of the handle member of the conventional flatware in FIG. 1A;

FIG. 3B is a side view of the sections of the handle member in FIG. 3A;

FIG. 3C show the cross-section of a handle section along line I-I in FIG. 3B;

FIG. 3D is a side view of the handle member shown in FIG. 3A;

FIG. 4A is a plan view of an assembly of service member and handle sections of the conventional flatware shown in FIG. 1;

FIG. 4B is a partial side cross-sectional view of the assembly in FIG. 4A;

FIG. 5A is a plan view of a hollow handle flatware according to one embodiment of the invention;

FIG. 5B is a side cross-sectional view of the hollow handle flatware in FIG. 5A;

FIG. 5C shows a cross-section of the flatware taken along line II-II in FIG. 5A;

FIG. 6A is a plan view of a main body of a hollow handle flatware according to one embodiment of the invention;

FIG. 6B is a side cross-sectional view of the main body shown in FIG. 6A;

FIG. 6C is a partial enlarged view of the main body shown in FIG. 6B;

FIG. 7A is a plan view of a handle part according to the invention;

FIG. 7B is a side view of the handle part shown in FIG. 7A; and

FIGS. 7C and 7D show different cross-sections of the handle part taken along lines and IV-IV in FIG. 7B.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Various embodiments of the hollow handle flatware 101 are described below with reference to FIGS. 5A to 7D. In the following description of different embodiments, similar components are designated with the same numeral reference and redundant description is omitted.

FIGS. 5A and 5B show an embodiment of a hollow handle flatware 101. The hollow handle flatware 101 has a main body 110 which, as is further illustrated in FIGS. 6A and 6B, includes a service portion 120 and a handle portion 130. The hollow handle flatware 101 also has a handle part 140 which is permanently fixed to the handle portion 130 of the main body 110 to form a hollow handle 150 of the hollow handle flatware 101. Although the hollow handle flatware 101 is shown as a fork in the various drawing figures, the invention is not limited to a fork but is applicable to other flatware, such as a knife, spoon or other flatware.

The service portion 120 of the main body 110 is formed at a service end 112 s of the main body 110. The service portion 120 can be in various forms similar to a service member 10 of a conventional flatware 1. For example, the service portion 120 is provided with fork tines 122 so as to form the hollow handle flatware 101 as a fork. The service portion 120 can also be in various other forms, such as a knife blade or a spoon bowl.

As FIGS. 6A and 6B show, the handle portion 130 of the main body 110 can be formed to have an elongated shape as part of the hollow handle 150. In the example shown in FIG. 6A, the handle portion 130 has an edge area 132 formed on the top surface of the handle portion 130 for joining to the handle part 140 by a joint 160, such as a welding line. The center area 134 on the top surface of the handle portion 130 partially defines the hollow chamber 152 inside the hollow handle 150 after the handle portion 130 joins the handle part 140 to form the hollow handle 150.

The handle portion 130 of the main body 110 can be formed to have various configurations. In the example shown in FIG. 6B, the handle portion 130 of the main body 110 can be bent in a transverse direction of the handle portion 130. For example, the handle portion 130 can be formed by bending a sheet material in the transverse direction of the handle portion 130. In one example, the handle portion 130 can have a wavy profile as is shown in the longitudinal cross-sectional view of FIG. 6B. The handle portion and the service portion are integrally formed from a resilient material, such as stainless steel, by molding or stamping, as is known in the art.

Additionally or alternatively, the handle portion 130 of the main body 110 can comprise a substantially flat portion 136 on the bottom surface of the handle portion 130. Such contact portion 136 is adapted to contact a tabletop surface T, after the hollow handle flatware 101 is set on the tabletop surface T, and prevent the hollow handle flatware 101 from shaking when the table is inadvertently bumped. In one example best shown in FIG. 6B, the contact portion 136 is formed to extend across the width of the handle portion 130 of the main body 110. In another example, the contact portion 136 smoothly merges into the remaining bottom surface of the handle portion 130 so that the bottom surface of the handle portion 130 has a continuously curved or wavy profile, as is shown in FIG. 6B.

As mentioned above, the main body 110 is formed as a single piece, in which the service portion 120 and the handle portion 130 are integrally formed. As an example, the main body 110 can be formed by stamping a continuous sheet material, as will be described in the embodiments below. In the example shown in FIG. 6B, the main body 110 can have a substantially uniform thickness t. For example, the thickness of the main body 110 can be about 3 mm. In another example, the service portion 120 and the handle portion 130 of the main body 110 can smoothly merge into each other at the bottom surface of the main body 110 and form a continuously curved or wavy profile. One skilled in the art will appreciate that the main body 110 can be formed by various other methods as described in the embodiments below.

In one example, the main body 110 of the hollow handle flatware 101 is formed with a step 114, preferably positioned at a dividing line between the service portion 120 and the handle portion 130. In the example shown in FIG. 6B, the step 114 is formed on a top surface of the main body 110 and extends down from the service portion 120 to the handle portion 130. The step 114 is configured to accommodate the front end 142 of the handle part 130, as is shown in FIG. 5A. In the example shown in FIG. 6A, the step 114 extends across the width of the main body 110 in its transverse direction.

The handle part 140 of the hollow handle flatware 101 can be elongated and extend between a front end 142 and a rear end 144 of the handle part 140. In one example best shown in FIG. 5A, the front end 142 of the handle part 140 is configured to conform to the step 114 on the main body 110. As is described in greater detail below, the bottom surface of the handle part 140 is adapted to be joined to the top surface of the main body 110, as is shown in FIG. 5B. The top surface of the handle part 140 forms at least part of the top surface of the hollow handle flatware 101 after the handle part 140 is fixed to the main body 110.

The handle part 140 can be formed to have any of various decorative shapes or pattern designs. In the example shown in FIG. 7A, the handle part 140 has a narrower front end 142 and a widened rear end 144. The handle part 140 can gradually transit from the narrower front end 142 to a widened rear end 144 along a longitudinal direction of the handle part 140. In the example shown in FIG. 7B, the handle part 140 can have a curved or wavy profile in a longitudinal direction of the handle part 140. For example, the handle part 140 can have wavy top and bottom surfaces in the longitudinal direction of the handle part 140, as is shown in FIG. 7B.

In the embodiment shown in FIGS. 7C and 7D, the handle part 140 is formed with one or more concave portions 146, which are provided to form part of the hollow chamber 152 inside the hollow handle 150 of the hollow handle flatware 101. The handle part 140 can be in the form of a curved shell with a curved profile in both the longitudinal and transverse directions of the handle part 140. The undersurface of the curved shell 140 defines a concave portion 146, which extends between the front and rear ends 142, 144 of the handle part 140. As one skilled in the art will appreciate, the concave portion 146 can be formed to have various other shapes.

Additionally or alternatively, the rim portion 148 of the shell shaped handle part 140 can be configured for joining to the edge area 132 on the top surface of the handle portion 130 of the main body 110 (see FIG. 6A) by various methods described below to form the hollow handle 150. In one example, the rim portion 148 of the shell shaped handle part 140 can have a similar profile to that of the edge area 132 on the top surface of the handle portion 130. When joining the shell shaped handle part 140 to the handle portion 130 of the main body 110, the rim portion 148 of the shell shaped handle part 140 aligns with and overlaps the edge area 132 on the top surface of the handle portion 130, resulting in a smooth joint 160 along the side surfaces of the hollow handle 150, as is best shown in FIG. 5B.

In one example, the handle part 140 is formed with a predetermined pattern on the top surface of handle part 140, so that the predetermined pattern faces upward toward the user when the finished hollow handle flatware 101 is set on a tabletop surface T. During manufacture, various handle parts 140 can be formed with various decorative patterns so that the handle parts 140 can be selectively used to combine with a “standard” or “stock” main body 110 to form a hollow handle flatware 101 with the pattern.

As is shown in FIGS. 5A and 5B, the handle part 140 is permanently fixed to the handle portion 130 of the main body 110 to form a hollow handle 150. For example, the handle part 140 and the handle portion 130 of the main body 110 can be welded to each other along a joint 160, as will be described in greater detail below. The joined handle part 140 and handle portion 130 enclose a hollow chamber 152 therebetween. As one skilled in the art will appreciate, the hollow chamber 152 inside the hollow handle 150 can effectively reduce the weight of the flatware 101 and/or the consumption of material used to form the hollow handle flatware 101.

The hollow handle flatware 101 is formed of various materials. For example, one or both of the main body 110 and the handle part 140 can be formed of stainless steel. The main body 110 and the handle part 140 can be formed of various other materials, including but not limited to nickel silver, sterling silver, or various other metal materials and various plastic materials. In one example, the main body 110 and the handle part 140 are formed of a same material, which can be advantageous in providing a more reliable joint 160 for the main body 110 and the handle part 140. In another example, the main body 110 and the handle part 140 can have a silver plated surface to provide an aesthetically appealing finish to the hollow handle flatware 101.

As mentioned above, a standard or stock main body 110 can be used to form various hollow-handle flatware patterns by simply attaching various handle portion designs thereto. Thus, dinner forks of various patterns/designs will have the same tine count, shape and fork length, but the pattern will be different as a result of the different attached handle portion 130. The same will be true for other flatware pieces, such as teaspoons, salad forks, etc. Moreover, the flat portion 130 not only provides stability for the flatware item when placed on a table, but the semi-circular cross-sectional shape, as shown in FIG. 5C, provides a more comfortable and stable grip so that the flatware has less tendency to rotate about its longitudinal axis when being handled. In addition, the use of a main body 110 as shown in FIGS. 5A-7D provides stability and strength at joint 160, as compared to the prior art hollow handle flatware depicted in FIGS. 1A-4B.

The hollow handle flatware 101 is formed by separately forming the main body 110 and the handle part 140 and joining the main body 110 and the handle part 140 as a unitary hollow handle flatware 101. Embodiments of manufacturing the hollow handle flatware 101 will be described in great details below.

The main body 110 of the hollow handle flatware 101 can be formed by various methods. In the example best shown in FIGS. 6A and 6B, the main body 110 can be formed from a single piece of material. For example, the main body 110 can be fowled by stamping a sheet material, such as a stainless steel sheet, to form the service portion 120 and the handle portion 130. In one example, the stamping process forms the folk tines 122 or other service member, such as a knife blade, and a spoon bowl, in the service portion 120. During the stamping process, the handle portion 130 is bent in a transverse direction of the handle portion 130 to form a continuously curved or wavy profile as is shown in FIG. 6B. In one example, a contact portion 136 is formed on the bottom surface of the handle portion 130. Additionally or alternatively, a step 114 is stamped on the top surface of the main body 110 between the service portion 120 and the handle portion 130. As one skilled in the art will appreciate, the main body 110 can be formed by various other methods, including but not limited to forging, swaging, and molding.

The main body 110 of the hollow handle flatware 101 can be formed in various shapes. In the example shown in FIG. 6B, the handle portion 130 of the main body 110 can have a curved or wavy profile in a longitudinal direction. Additionally or alternatively, the handle portion 130 can have a linear profile in a transverse direction, as is best illustrated by the cross-section of the hollow handle 150 in FIG. 6B. In one example, part of the linear portion can constitute a contact portion 136 on the bottom surface of the handle portion 130, so as to provide stability to the hollow handle flatware 101 after it is set on a tabletop surface T.

The handle part 140 of the hollow handle flatware 101 can be formed by various methods. For example, the handle part 140 can be formed by stamping a sheet material, such as a stainless steel sheet. One skilled in the art will appreciate that the handle part 140 can be fowled by various other methods, including but not limited to forging, swaging, and molding.

The handle part 140 of the hollow handle flatware 101 can be formed to have various shapes. For example, the handle part 140 can be formed with a concave portion 146, which forms part of the hollow chamber 152 inside the hollow handle 150 of the hollow handle flatware 101. In one example, the concave portion 146 can continuously extend between the front end 142 and the rear end 144 of the handle part 140. Additionally or alternatively, the top surface of the handle part 140 can be formed with a predetermined pattern to enhance the aesthetic appearance of the hollow handle flatware 101. In one example, the top surface of the handle part 140 has a continuously curved or wavy profile, as is shown in FIGS. 7B to 7D.

The separately formed main body 110 and handle part 140 can be permanently joined to each other to form a hollow handle flatware 101 by various known methods. It is preferred that the handle part 140 is welded onto the main body 110 and join the main body 110 to form a unitary piece. In one example, a joint 160 connects the rim portion 148 of the handle part 140 to the edge area 132 on the top surface of the handle portion 130 of the main body 110. Additionally or alternatively, the joint 160 can extend between and join the front end 142 of the handle part 130 and the stepped portion 114, as is shown in FIG. 5A. In one embodiment, the joint 160 is formed to seal between the connecting parts to prevent moisture or dust from entering the hollow chamber 152 inside the hollow handle 150 during normal use and washing of the hollow handle flatware 101. As one skilled in the art will appreciate, various other known methods can be used to join the main body 110 and the handle part 140 and form a unitary piece of hollow handle flatware 101.

One or more finishing process steps can be carried out to enhance the appearance of the hollow handle flatware 101. In one example, the hollow handle flatware 101 can be subjected to a trimming process to remove burs or bumps, which can result from joining the main body 110 and the handle part 140. Additionally or alternatively polishing can be performed and/or a plating process, such as silver plating, can be carried out to provide an enhanced surface finishing for the hollow handle flatware 101. The plating process can be carried out either before or after joining the main body 110 and the handle part 140 to form the hollow handle flatware 101.

Thus, while there have shown and described and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto. 

1. A hollow handle flatware comprising: a main body having a service portion and a handle portion which are integrally formed with each other, the main body having a length substantially defining a length of the hollow handle flatware, the handle portion having an upper surface and a bottom surface, the bottom surface configured for positioning on a table top; and a handle part formed separately from the main body and permanently fixed to the upper surface of the handle portion of the main body to form a hollow handle; wherein the handle part and the handle portion of the main body enclose a hollow chamber therebetween.
 2. The hollow handle flatware of claim 1, wherein the handle part is permanently fixed to the handle portion by welding.
 3. The hollow handle flatware of claim 1, wherein the main body comprises a step formed on the upper surface of the main body between the service portion and the handle portion for receiving a front edge of the handle part.
 4. The hollow handle flatware of claim 3, wherein the step extends across a transverse direction of the hollow handle flatware.
 5. The hollow handle flatware of claim 1, wherein the service portion of the main body smoothly transits into the bottom surface of the hollow handle flatware.
 6. The hollow handle flatware of claim 1, wherein the handle portion of the main body forms at least part of a bottom surface of the hollow handle flatware.
 7. The hollow handle flatware of claim 1, wherein the handle portion of the main body comprises a substantially flat contact portion for contacting a tabletop surface when the hollow handle flatware is set on the tabletop surface, and wherein the contact portion on the handle portion of the main body extends across a width of the handle portion of the main body.
 8. The hollow handle flatware of claim 1, wherein the main body and the handle part are each formed of a sheet material.
 9. The hollow handle flatware of claim 1, wherein the main body and the handle part are formed of a same material.
 10. A method of making a hollow handle flatware, the method comprising: providing a main body having a service portion and a handle portion which are integrally formed with each other, the main body having a length substantially defining a length of the hollow handle flatware, the handle portion having an upper surface and a bottom surface, the bottom surface configured for positioning on a table top; providing a handle part separately from the main body; and permanently fixing the handle part to the upper surfaced of the handle portion of the main body; wherein the handle part and the handle portion of the main body enclose a hollow chamber therebetween.
 11. The method of claim 10, wherein the step of providing a main body comprises stamping a sheet material to form the main body.
 12. The method of claim 10, wherein the step of providing a main body comprises forming a contact portion on a bottom surface of the main body, the contact portion extending across a width of the main body.
 13. The method of claim 10, wherein the step of providing a main body comprises forming a step on the top surface of the main body and between the service portion and the handle portion for receiving a front edge of the handle part.
 14. The method of claim 13, wherein the step of providing a handle part comprises forming a front end of the handle part to conform with the step.
 15. The method of claim 10, wherein the step of providing a handle part comprises forming a predetermined pattern on the handle part by at least one of stamping, forging, swaging, and molding.
 16. The method of claim 10, wherein the step of fixing comprises welding.
 17. The method of claim 10, wherein the main body and the handle part are formed of a same material.
 18. The method of claim 10, further comprising plating both the main body and the handle part to provide a finished surface for the hollow handle flatware. 